1 Overview
In recent years, with the increasing market share of petrochemicals, coal mines, non-ferrous minerals and other ancillary equipment, the existing production capacity, production equipment and process management procedures of Xinjiang pressure vessels have been unable to meet the needs of market product manufacturing. In order to occupy a greater competitive advantage in the fierce market competition and seize the golden opportunity of development, Zhongjian Xinjiang Industrial Equipment Installation Co., Ltd. urgently needs to improve the manufacturing capacity of pressure vessel products and accelerate the technical transformation of existing equipment. Improve the level of technical equipment to achieve rapid and sustainable development. The CO 2 gas shielded automatic welding is welding equipment has a mature integration, design of an efficient, low labor intensity of automated welding equipment.
The device consists of the following parts:
(1) Welding oscillating device An auxiliary device for efficient welding , which has a linear oscillating function. Various oscillating parameters such as oscillating mode, oscillating amplitude, oscillating speed, swing center position and left and right dwell time can be adjusted to improve weld formation. Increase productivity.
(2) The flexible rail is clamped on the cylinder for the special mechanism of walking and positioning of the welding trolley. The structure is easy to assemble and disassemble and easy to position; the structure is reasonable and the weight is light; it has certain strength and flexibility, wear resistance and corrosion resistance. The track is attracted to the workpiece with a powerful magnet, which is easy to install and remove.
(3) The walking vehicle adopts the welding equipment of the driving wheel to walk on the track. It is widely used in horizontal butt welding, especially suitable for medium and thick plate welding . It can also be used for fillet welding and horizontal welding by adjusting the position and angle of the welding torch. The body of the car and the control panel are integrated, and they can be welded while walking on the track.
2. Project Overview
At present, the circumferential seam welding method in the cylinder is relatively advanced by using a cantilever CO 2 gas shielded welding machine for welding , but the length of the cantilever expansion and contraction is limited, and there is no power for the ultra-long cylinder. Some large-diameter cylinders are provided with a rice-shaped support. It is even more unusable and can only be welded to one inner ring seam. In order to overcome the above difficulties, the company added a walking trolley, a welding oscillating device and a water-cooled welding torch on the basis of the original CO 2 welding equipment to form a CO 2 gas protection automatic welding machine, and laid a track in the cylinder to realize the full automation of the ring seam in the pressure vessel. Welding . The improved CO 2 gas protection automatic welding machine can not only weld multiple inner ring seams at the same time, but also realize one or eliminate the adverse effect of the axial turbulence of the cylinder during the rotation on the welding .
3. Technical characteristics of the project
The CO 2 gas protection automatic welding machine for the ring seam in the sleeve body adopts the stepless speed regulation trolley as the carrier body, and the wire feeder, the welding oscillating device and the welding gun with circulating cooling are fixed to the trolley, and the welding gun is realized by the welding oscillating device. The weld direction oscillates left and right to improve weld formation and increase production efficiency. At the same time, the flexible track is arranged along the ring in the cylinder, and the magnetic steel block is positioned on the side of the weld, and then the circulating cooling water tank is equipped for automatic welding of CO 2 gas protection, and the inner ring seam is continuously welded and welded. After non-destructive testing, the product design requirements are met, as shown in Figure 1 and Figure 2.
Figure 1 Composition of CO 2 gas protection automatic welding machine
1. CO 2 gas cylinder 2. Gas mixer 3. Magnetic steel block 4. Flexible track 5. Cylinder
6. Adjustable speed roller frame 7. Circulating water-cooled welding torch 8. Sliding mechanism 9. Welding oscillator
10. Wire feeder 11. Speed ​​control car 12. Circulating water tank 13. Welding power supply
14. Argon bottle
In Figure 1, the CO 2 gas protection automatic welding machine determines multiple sets of mature welding parameters for different materials and thicknesses. The welding protection gas uses CO 2 and Ar mixed gas, and the left, middle and right of the welding oscillating device stays. The time, the width of each swing, and the current and voltage of the welding power source, the wire feeding speed of the wire feeder, and the running speed of the trolley and the roller frame are all set according to the actual welding conditions.
In the flexible track processing of Fig. 2, a circular hole in which a magnetic steel block is placed is drilled on the flexible track, and the magnetic steel block is placed in the hole to be adsorbed in the vicinity of the annular groove in the cylinder body, and the flexible track is matched with the groove of the welding trolley wheel.
When the welding operation is performed, the operator operates in the cylinder. In order to prevent the arc from being too strong, the arcing device is provided on the head of the welding gun.
Figure 2 Flexible track
1. Track base layer 2. Hole 3. Track
4. Analysis of economic benefits
The CO 2 gas protection automatic welding machine can complete the welding of the ring seam in the cylinder, which can greatly improve the welding efficiency of the gas shielded welding and the welding quality of the weld , and save the repair cost of the weld. After welding test, the quality of the weld can reach 100% UTII. Taking Q245R, δ=22~38mm, φ4000mm rotary kiln ring joint welding as an example, the welding , grinding and rework of a ring seam can save costs by 5.57 yuan/m compared with the original process. The whole plant is calculated according to the workload of contracting φ4000mm rotary kiln. In 2012, the introduction of this new process generated economic benefits of 65,700 yuan for the pressure vessel plant.
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